Devices for suspending a foot within a shoe and shoes incorporating such devices

ABSTRACT

An improved sole construction for use in shoes. The sole construction consists of a hammock-like lattice formed of medium to high modulus polymers, or a lightweight metal alloy. The lattice substantially conforms in topography to the foot, or a weight-bearing portion thereof (such as the heel or forefoot). The lattice may be disposed on, and supported by, a resilient frame, or secured directly to the shoe upper. The lattice supports the foot while suspending it slightly, even during gait, above the interior base of the shoe. The suspended portions of the foot are thusly protected from the shock of striking a surface (such as the ground, during gait), and are gently supported while bearing a load.

RELATED PATENT APPLICATIONS

[0001] This application is a continuation in part of, and claimspriority from, U.S. Patent Application No. 60/202,009, filed on May 4,2000.

[0002] This application is a continuation, and claims priority from,U.S. patent application Ser. No. 09/667,192, filed on Sep. 20, 2000.

FIELD OF THE INVENTION

[0003] The invention relates to footwear, namely the interior solestructures of shoes. In particular, the invention relates toconstructions for use as an interior sole of a shoe, to wholly orpartially suspend a foot above the base of the shoe, even during gait.

HISTORY OF THE RELATED ART

[0004] In recent years, the increasing popularity of shoes designed forenhanced comfort has led to a number of improvements to the insolestructure of different types of shoes. Innovations in flexiblecushioning materials, such as the development of molded ethylene vinylacetate (EVA) outsoles and polyurethane foam insoles, have enabledmanufacturers to provide a degree of shock attenuation in dress shoestypically reserved to athletic shoe designs. Integration of orthoticstructures, such as heel cups, into shoes can also provide the wearerwith better support and greater stability during gait.

[0005] Many such improvements have had their genesis in athletic shoedesign. For example, the desire to enhance the performance capabilitiesof running shoes led to the development of midsoles with fluid or gasfilled bladders embedded at strategic points for use in absorbing energytransmitted to the shoe during gait, and releasing it afterward (arecent iteration of the bladder technology is found in U.S. Pat. No.5,987,780). A similar goal is targeted in shoes which include atrampoline-like structure incorporated into the heel and/or otherregions of an otherwise cushioned midsole (see, e.g., U.S. Pat. Nos.5,070,627 and 5,561,920). In the trampoline design, a grid formed ofresilient fibers is stretched tautly beneath strike points of the foot,such as the heel. In both the trampoline and bladder designs, the energyreturn system acts like a spring, compressing on application of a force,then returning to its original shape on removal of the force.

[0006] While each of the aforementioned designs has its advantages, allalso have limitations. For example, soft molded insoles and outsoles canbecome uncomfortable if their contours do not match those of thewearer's foot. In the trampoline and bladder designs, the springinesswhich improves performance if used at discreet points in an otherwiseconventional midsole design can cause the shoe to become unstable ifadded throughout the midsole. Foot fatigue is also an issue for all ofthese designs, which still rely on the foot to absorb and deflect asignificant amount of the force generated during gait.

[0007] Further, customizability is largely lacking among existing shoedesigns, most of which allow for little, if any, modification of themidsole by the wearer. As an alternative, one could use a customdesigned orthotic device for insertion into a conventional shoe whichaddresses the wearer's specific orthotic needs. However, such deviceshave limited adaptability to different shoe structures (e.g., most arenot suitable for use in shoes with raised heels), and are usuallyexpensive to purchase.

SUMMARY OF THE INVENTION

[0008] The invention provides shoes with an improved sole structure, aswell as removable orthotic soles, which each overcome many of thelimitations of the prior art by suspending the foot above the base of ashoe. The invention also allows for relatively low cost manufacture of alightweight shoe, by providing means by which the inventive sole andshoe upper may be manufactured as a unitary structure.

[0009] In all of the embodiments of the invention, the inventionincludes a hammock-like lattice which substantially conforms intopography to the foot, or a weight-bearing portion thereof (such as theheel or forefoot). Although the lattice may optionally contact or beincorporated with components which provide for energy return andcushioning, the principal role of the lattice is to support and controlthe position of the foot. This function is provided by suspending thefoot slightly above the base of the shoe at all times, even during gait.In this manner, the suspended portions of the foot are largely protectedfrom the shock which is transmitted upwardly from the ground duringgait, and are gently supported while bearing a load, an especiallyuseful feature when standing for a long period of time.

[0010] In one aspect, the invention consists of a shoe in which thelattice comprises the all or a part of the interior sole structure ofthe shoe (including the midsole and insole layers). The shoe furtherconsists of an upper to encircle all or part of the wearer's foot, andan outsole adapted to engage the ground.

[0011] In one such embodiment, the lattice is disposed within the shoeon a scaffolding consisting of an annular frame supported vertically byside pillars. In particular, a resilient annular frame is fitted alongthe inner perimeter of the shoe upper and may optionally be secured byattachment means to the upper. The lattice is stretched between thesides of the scaffolding in the same plane as, but lying slightly above,the interior base of the shoe.

[0012] The frame is vertically supported in the shoe by a multiplicityof side pillars extending downwardly from the frame along the innersurface of the upper. Depending on the degree of vertical supportrequired for the frame and lattice structure, the side pillars may alsoextend along the width of the insole liner to form “U” shapedstructures, in which the bight of each “U” rests on the base of theshoe.

[0013] The lattice is preferably woven, molded or extruded to possesscontours which conform substantially to the topography of the sole of awearer's foot. The lattice is also constructed of high tensile strength,low “springiness” fibers (e.g., a polymer or lightweight metal) woven toform a mesh which deforms to the specific topography of a wearer's foot.The fibers are stretched between the sides of the frame at a relativetension sufficiently low to allow desired portions of the lattice todeform on contact, but sufficiently high to maintain the foot insuspension above the base of the shoe.

[0014] Advantageously, the lattice is preferably provided with discreteregions having different degrees of elasticity, to provide control ofgait. For example, the midfoot region of the lattice underlying the archof the foot (medial midfoot) may be less elastic than adjacent regionsof the lattice, to provide for control of supination (rolling inward)during gait. Such regions of varying elasticity may be provided byincreasing the relative tension of lattice fibers within a given region,or by varying the composition of the lattice, as in providing a materialof low elasticity along the medial midfoot region, and more elasticmaterial in adjacent regions.

[0015] In one aspect of the inventive shoe described, the annular frameincludes rotation means at varying points (e.g., at the forefoot andheel), to allow the frame to vertically bend to, for example, allow theframe to follow the curvature of the shoe upper and outsole.

[0016] In another aspect of the inventive shoe described, the sidepillars include shock absorption means, such as a piston or closed cellfoam bar.

[0017] In another aspect of the inventive shoe described, energy returnand/or cushioning means, such as, respectively, an air bladder orpolyurethane foam pad, are incorporated into the interior base of theshoe to contact the underside of the lattice at one or more strikepoints along the foot; or are incorporated within the lattice itself atsuch points.

[0018] In another aspect of the inventive shoe described, the upper,scaffolding and, optionally, the lattice are integrally formed as aunit.

[0019] In another embodiment of the invention, a shoe is provided inwhich a lattice is disposed substantially as described above, exceptthat the annular frame only extends around the inner perimeter of theupper adjacent to one or more weight-bearing regions of the foot, suchthat only those region(s) of the foot are suspended in the lattice.

[0020] In another embodiment of the invention, the frame and lattice areconstructed substantially as described above, except that the entiresole structure may be removed from the shoe for use as an independentorthosis.

[0021] In another aspect of the both the shoe and orthosis embodimentsof the invention, the annular frame includes adjustment means whichallow the user to increase or decrease the tension applied to thelattice at discreet points.

[0022] In another aspect of the both the shoe and orthosis embodimentsof the invention, the lattice is attached to the annular frame along aremovable annular ring, to permit the lattice to be repaired, replacedor substituted with a lattice of differing structural characteristics;e.g., for, a lattices having different contours.

[0023] In yet another aspect of the invention, the lattice is formed asan integral part of the shoe upper. In this embodiment, the shoe uppersupports the lattice, in lieu of the annular frame, which is thereforeabsent.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is a representative scaffolding for use in a men's shoe,without a heel.

[0025]FIG. 2 is the scaffolding of FIG. 1, on which a woven lattice isdisposed.

[0026]FIG. 3 is a side view of a portion of a scaffolding of theinvention, including a rotating pin hinge in a flex point along theannular frame of the scaffolding, as well as a shock-attenuating rubberbar in side pillars of the scaffolding.

[0027]FIG. 4 is a top view of a portion of the woven lattice of FIG. 2,showing fibers of the mesh.

[0028]FIG. 5 is a side view of a scaffolding with a lattice attached bythreading through grommets in the annular frame.

[0029]FIG. 6 is an exploded side view of a scaffolding with a removablerim thereon for attachment of a lattice.

[0030]FIG. 7 is a representative scaffolding in which the side pillarsdo not extend beneath the lattice.

[0031]FIG. 8 is a top view of a portion of a lattice, showing use ofvarying materials throughout to provide control of gait.

[0032]FIG. 9A is a top view, and FIG. 9B is a cross section of FIG. 9A,showing a portion of a lattice, showing use of fibers in discreteregions of the lattice under differing degrees of tension, relative toadjacent regions of the lattice, to provide control of gait.

[0033]FIG. 10 is a top view of a portion of a lattice, showing use ofvarying fiber densities throughout to provide control of gait.

[0034]FIG. 11 is a side view of a shoe of the invention, into which thescaffolding and lattice structure is inserted. The shoe is shown in atransparent outline in the drawing.

[0035]FIG. 12 is a side view of a shoe of the invention, in which theshoe upper and scaffolding are formed as a unitary piece.

[0036]FIG. 13 is a side view of a ¾ length scaffolding, showing thelattice terminating forward of the medial midfoot region (at the arch),where conventional cushioning is used to support the forefoot.

DETAILED DESCRIPTION OF THE INVENTION

[0037] I. Functionality

[0038] A. Definitions.

[0039] Because the invention provides an unprecedented structure for useas the interior sole of a shoe, there is no conventional terminologywhich suffices to readily describe what the invention is. Certainly, theinvention replaces the insole (lining contacted by the foot) and all ormost of the midsole structure (cushioning and support construction)present in most shoe types. In some embodiments, the invention alsoreplaces a substantial part of the outsole (e.g., those embodiments inwhich outsole material is joined directly to the inventive scaffolding).In yet other embodiments, the invention also provides the shoe upper(e.g., those embodiments in which the upper is a unitary part of theinventive scaffolding and lattice structure).

[0040] Hence, to reflect all of the attributes of the invention, thescaffolding and lattice, in combination, will be collectively referredto herein as the “sole structure” of the invention. The sole structureis referred to as suspending the foot above the “base” of a shoe, whichis essentially the interior surface of a shoe outsole, to the extentpresent. The term “upper” will be understood to refer to the materialwhich extends over the top of the foot, which may comprise, withoutlimitation, a solid or banded piece of upper material (leather, canvas,microfiber, woven fabric, and the like).

[0041] B. Suspension of the Foot.

[0042] In general, all embodiments of the invention described belowshare a common feature, which is a lattice “hammock” for the foot. Whenplaced into the lattice, the foot remains in suspension above the shoebase, except for discrete portions of the foot which may be allowed tocontact the insole during gait in certain embodiments (e.g., where thedevice of the invention lacks a frame extending around the toes, theportion of the toes forward of the metatarsal heads may be allowed toengage the shoe base to push off therefrom during gait).

[0043] Although under tension (which may vary at points throughout thelattice), the lattice is not tautly strung within its scaffolding, anddoes not primarily serve as an energy return system (e.g., atrampoline-like structure). Rather, the invention provides gentle,stable, controlled support by pulling and holding the foot, rather thanpushing it into position within a shoe.

[0044] II. A Scaffolding

[0045] A. Scaffolding structure.

[0046] Referring to FIG. 1, a resilient polymer scaffolding 10 is shown,which is adapted to support a lattice according to the invention as theinterior sole construction of a men's size 11 (US) dress shoe (a deviceincluding both scaffolding 10 and lattice 30, as later described, isshown in FIG. 2). The dimensions of the scaffolding described hereconform to such a shoe; however, with an understanding of the inventionprovided by this disclosure, those of ordinary skill in the art willreadily be able to modify the stated dimensions for use of the inventionwith other size and style shoes.

[0047] As shown in FIG. 1, scaffolding 10 consists of annular frame 11with lateral and medial side walls (elements 12 and 13, respectively),defining a forefoot region 14 (extending rearwardly from toe end 15 toline A-A), a midfoot region 16 (lying between line A-A and line B-B),and a heel region 17 (extending rearwardly from line B-B to heel end18). As is apparent from FIG. 1, annular frame 11 is contoured to followthe inner perimeter of a shoe upper (not shown). As shown in FIG. 9,annular frame 11 may also be integrated into the upper, so the upper,scaffolding and, if co-molded with the scaffolding, lattice, all form aunitary upper and midsole shoe construction. The latter embodiment isespecially well-suited to use with an upper formed of a stretchmaterial, such as a fabric woven with Lycra™, or a microfiber.

[0048] Vertical support of annular frame 11 is provided by severalstructures. First, “U” shaped members (consisting of side pillars 19Aand 19B, joined respectively by bights 19C and 19D; and side pillars 20Aand 20B, joined respectively by bights 20C and 20D) extend downwardlyfrom annular frame 11 to support the frame within a shoe, in thoseembodiments in which annular frame 11 is not an integral part of theshoe upper. Side pillars 19 A and B define a gap 21 beneath where theball of a foot would rest in forefoot region 14; and side pillars 20 Aand B define a similar gap 23 in heel region 17. Additional gaps inscaffolding 10 are defined by the space separating side pillar 19 B andtoe end 15 (gap 22, underlying the point at which toes of a foot wouldrest in forefoot region 14); the space separating side pillar A and heelend 18 (gap 24, underlying the point at which a heel would rest in heelregion 18); as well as by the space separating side pillars 19 A and 20B (gap 25, underlying the point at which the arch of a foot would restin midfoot region 16).

[0049] Each defined gap in the scaffolding provides space fordisplacement of the lattice as weight is placed thereon or the footflexes. Gap 22 is angled upwardly (at a conventional angle of toespring) to provide room for displacement of lattice 30 (see, FIG. 2)during the toe-off phase of gait. Gap 21 allows space for forefootregion 14 to displace downwardly as weight is transferred forward soload is carried by the toes. Gap 24 provides room for downwarddisplacement of lattice 30 (see, FIG. 2) as weight is shifted backtoward the heel, and gap 23 allows for vertical movement as needed inheel region 17. Gap 25 further allows room for frame 11 to be adaptedfor use in both flat heeled shoes (no flex in frame, as shown in FIG. 1)and in heeled shoes (where frame 11 would be flexed to raise heel region17 to the degree necessary to seat it above the heel of a shoe; see,example shown in FIG. 5).

[0050] Additionally, mechanical flexure along the length of thescaffolding, in relation to motion of the foot during gait, is providedby the angle of toe spring (from 0°, wherein no flex is allowed, toabout 40°, where substantial assistance in toe-off is provided). Flexuremay also be provided by constructing the “U” shaped members ofscaffolding 10 in a rocker configuration; i.e., one in which the bight19D of the “U” extending from forwardmost side pillar 19B, and bight 20Cextending from rearwardmost side pillar 20 A, are raised slightly abovethe plane of midfdot side pillars 19A and 20B, as shown in FIG. 1. Analternative rocker configuration which allows for maximal rocking motionfrom heel to toe is one in which a single midfoot side pillar is usedacross the width of gap 25, in lieu of side pillars 19A and 20B. In thelatter embodiment, side pillars 19B and 20A are raised above the planeof the single midfoot pillar; or one or both is absent.

[0051] Further means to permit rotation of annular frame 11 itself aredepicted in FIG. 3; in particular, rotation means are provided at flexpoints in the frame. As shown, such rotation means are active onesconsist of top mounted rotating pin hinges (see, e.g., pins 35 and 36)disposed at the top of, respectively, any or all of side pillars 19A,19B, 20A and 20B, on both lateral side 12 and medial side 13 of frame11. It will be appreciated that other rotation means, both active andpassive, may be employed in lieu of, or in conjunction with, rotatingpin hinges as shown. For example, bars 50 of a flexible material, such aclosed cell polyurethane, ethylene vinyl acetate, or rubber, areembedded at discrete points to enable them scaffolding 10 to bend and/orcompress, thereby providing flexibility and shock attenuation to thedevice. Alternatively, tension springs, pistons, or the like may beused.

[0052] Means for allowing adjustments to the height of frame 11 may alsobe provided. For example, click-stops may be provided in opposing sidepillars extending downwardly from both lateral side 12 and medial side13. Such click-stops enable one to raise and lower all or a part of theframe to a desired height within a shoe. Alternative adjustment meansare extant in the art; for example, pistons, air or fluid filledbladders, or electronically-controlled solenoids could be used.

[0053] Lattice 30 is shown in FIG. 2, in place on scaffolding 10. Inthis embodiment, lattice 3Q is attached around the circumference ofannular frame 11. The attitude of lattice 30 varies throughout itslength, depending on the nature of support and gait control to beprovided by the device.

[0054] For example, a contour in annular frame 11 intended for providingadded support, and control of gait, is shown at raised edge 26, whichconsists of a convex portion of medial wall 13 spannning midfoot region16. When lattice 30 is in place as shown in FIG. 4, its medial side 31(medial to line C-C) lies in a higher plane along raised edge 26, toprovide support for the arch of a foot. Increasing the cant of medialside 31 (by increasing, the convexity of raised edge 26, as compared tolateral side 12 of frame 11) provides for a higher arch support, whilelowering the cant provides for a lower arch support.

[0055] Additionally, canting raised edge 26 upward in comparison tolateral side 12 of frame 11 stretches lattice 30 across midfoot region16 of the frame (over gap 25), thereby making the lattice morerigid-along the midfoot region than along the heel and forefoot regionsof the device. However, if a high arch support with less rigidity in thelattice is desired (to give a more cushioned feel to the arch support),the weave, thickness or fiber content of the lattice may be variedwithin the midfoot region.

[0056] For example, as shown in FIG. 2, a raised arch support isprovided by upwardly canting raised edge 26 of medial frame wall 13.However, the variation in tension on the lattice in the midfoot regionas compared to the heel and forefoot areas may be lessened by providinga looser weave in the midfoot region (see, FIG. 9). Other modificationsto the rigidity of the lattice at varying points therein may be providedby using layered mesh at discrete points, varying the thickness or weaveof fibers in the lattice (making them less or more susceptible toincreases in tension), or by using fibers of differing materials atdiscrete points in the lattice. For example, FIG. 8 shows a twill weavelattice in which a high modulus material, such as glass fibre nylon, isused as both the warp and weft along the midfoot region, and anelastomer having a low modulus is used as the weft (against a glassfibre nylon warp) in the heel and forefoot regions. Further details,concerning differing materials and constructions for use in the latticeare provided elsewhere below.

[0057] It will be appreciated that the attitude of lateral wall 12 ormedial wall 13 may be raised or lowered at discrete points in annularframe 11, as compared to other portions of the frame, to providefunctionalities other than arch support. For example, as shown in FIG.2, toe end 15 cants upwardly along the length of gap 22 to as-much as a40° angle of toe spring to provide additional support to themetatarsals, and to aid in toe-off during gait, by providing an angledsurface along the lattice for the toes to engage and push off from.Excellent metatarsal support may also be provided by eliminating toe end15, and terminating scaffolding 10 at side pillar 19B in forefoot region14. Such as shortened scaffolding allows the leading edge of the deviceto terminate just forward of the metatarsal heads, allowing the toes topush against the shoe insole during gait. As shown in FIG. 13,additional cushioning for the forefoot may be provided by supplying apad, such as a foam mat or air-filled bladder 90, forward of thelocation shown for side pillar 19B.

[0058] A number of structural adaptations of scaffolding 10 for use indifferent shoe types may be made. For example, for use in a sandalconfiguration, side pillars. 19A, 19B, 20A and 20B may be absent (sothat annular frame 10 rests on, and is secured directly to, the outsoleof the sandal), or shortened to form downwardly extending flanges, theends of which engage the outsole, as shown in FIG. 7 (see, flanges 79Aand B, 80A and B [B is in phantom], 81 A and B [B is in phantom], and 82A and B). For use in a woman's pump, heel end 18 may be canted oradjustable upwardly, as compared to midfoot region 16, and side pillar20A may be absent.

[0059] The degree to which the attitude of lattice 30 is altered atdiscrete points to provide desired support and gait control will varydepending on the kind of support or gait control sought. Those ofordinary skill in the art are fully capable of determining, for example,an appropriate angle for use in cushioning the metatarsals (e.g., bycanting forefoot region 34 of the lattice upwardly to vary 20 to 10°from level); or for providing control over pronation (by raising lateralside 32 of the lattice 5° to 40° with respect to medial side 33) andsupination (by raising medial side 31 of the lattice with respect tolateral side 32); or for stabilizing the heel (by deepening theconcavity of the lattice in heel region 37 to cup the heel). Thus,although particular dimensions are given for the scaffolding as shown inFIG. 1, to provide a lattice having the particular attitude shown inFIG. 2, it will be appreciated that the invention encompassesmodifications to the dimensions shown, which dimensions are within theordinary skill of the art to achieve, in view of the present disclosure.

[0060] In that respect, the scaffolding of FIG. 1 is 11.55 inches (″) intotal length, and has the following dimensions (also indicated in thedrawing): TABLE 1 Dimensions of Scaffolding to 1/100^(th) of an inch(FIG. 1). Forefoot Region (14) Midfoot Region (16) Heel Region (17) Toeend 15 = .49″ H Raised edge 26, on medial Heel end 18 = .35″ H side 13 =.90″ H at forward end; .68″ in H at rearward end Annular frame 11,Annular frame 11, Annular frame 11, extending from edge to extendingfrom edge to extending from edge to edge of gap 21 = .55H, on edge ofgap 25 = .58″ H, on edge of gap 23 = .61″ H, on lateral side 12; and.34″ on lateral side 12 lateral side 12; and .52″ H medial side 13 onmedial side 13 Side pillar 19B = 1.46″ H Side pillar 19A = 1.42″ in HSide pillar 20A = l.15″ in H from base to top of annular from base totop of annular from base to top of annular frame 11 frame 11; Sidepillar frame 11 20B = 1.4l″ H Side pillar 19B = 4.03″ W, Side pillar 19A= 4.55″ W, Side pillar 20A = 3.63″ W, from lateral side 12 to and, Sidepillar from lateral side 12 to medial side 13; 1.04″ W, 20B = 3.65″ Wboth medial side 13; 0.94″ W, from forwardmost to measured from lateralside from forwardmost to rearwardmost edge of bight 12 to medial side13; 1″ W, rearward most edge of bight from forwardmost to rearwardmostedge of the bights

[0061] B. Scaffolding materials.

[0062] Scaffolding 10 may be constructed of any resilient, durable,lightweight material, preferably one capable of extrusion or injectionmolding. Particularly well-suited materials include polypropylene,non-thermoplastic polymers such as aramid polymer fibres (e.g.,Kevlar®), nylons (including glass fibre nylons), carbon graphite,polyester resins, liquid crystal polymers, or lightweight metals, suchas titanium and aluminum. If scaffolding 10 is to be incorporated into ashoe, upper, materials suitable to allow attachment of the shoe upperfabric to annular frame 11 may be selected by one of ordinary skill inthe art. As requited, elements of other composition, such as metallichinge parts, may also be incorporated into the scaffolding structure.

[0063] III. Lattice

[0064] As shown in FIG. 2, lattice 30 has lateral and medial sides(respectively, elements 31 and 33), and includes a forefoot region 34(extending rearwardly from toe end 35 to line A-A), a midfoot region 36(lying between line A-A and line B-B), and a heel region 37 (extendingrearwardly from line B-B to heel end 38). As shown in FIG. 4, thelattice of FIG. 2 is constructed of individual fibers, which are woveninto an twill weave, open pore mesh (FIG. 4). A number of alternativesto the twill weave configuration for the lattice, including non-wovenfabrics (see, e.g., FIG. 10), are also suitable for use in theinvention, and are described below.

[0065] In all such embodiments, the principal load beating component ofthe lattice is a non-elastomeric polymer or metal based homogenous orcomposite fibre or yarn. Non-elastomeric materials useful in both wovenand non-woven embodiments of the lattice are those which retain a highto medium modulus under increasing strain (little deformability);possess little or no tendency toward “sag and creep”; possess relativelyhigh tensile strength (low elongation to break), and high dimensionalstability (which may be an inherent property of the material, or oneimparted during manufacture, as in by resin coating and heat setting).

[0066] Lattice 30 may be constructed entirely of a high to mediummodulus material, preferably in a weave which varies from medium texture(from 10 to 35 threads per centimeter) in areas requiring lessstiffness, to fine texture (35 threads per cm., or greater) in areasrequiring greater stiffness. An especially advantageous embodiment isone in which the lattice is constructed of a mixture of high/medium andlow modulus materials, to provide either a one-way stretch lattice (withthe stretch preferably running in the warp direction [side to side]), orone in which stretch is provided to a greater degree in the warpdirection, than from heel to toe (weft direction).

[0067] To this end, a relatively low modulus material is interwoven withhigher modulus materials to form a mesh having a higher modulus (littlestretch) in the warp direction and a low modulus (stretch) in the weftdirection. Preferably, the composition of the lattice varies so thathigh to medium modulus materials are present in areas requiring greaterrigidity (e.g., beneath the arch, heel and metatarsal heads of thefoot), and low modulus materials are present in areas requiring greaterstretch (e.g., under the toes). Additionally, very low modulus materials(e.g., cotton or spandex) may be interwoven into a mesh as an additionalply to provide the lattice with a softer hand.

[0068] Suitable materials for use as the load-bearing components of thelattice include homogenous or composite fabrics of: MATERIAL TYPECOMPARATIVE VALUES Aramid polymers (e.g., Kevlar ®, aramid Highertensile strength than glass fibre fibers from DuPont; Twaron ®, aramidnylon and carbon fibre; lower fibres from Twaron) compressive strengththan glass fibre nylon and carbon fibre; medium modulus. Example: Kevlar49 (1140 denier): 23 gpd (tensile strength); 900 gpd initial modulus;creep rate v. log time (40-58% loading) 0.020; elongation 2.5%. Nylons(30 to 1500 denier) Lower modulus than carbon fibre or Ripstop aramidfibres; strong; relatively low cost. air textured nylon (Cordura ®, fromExample: DuPont) Cordura ®, with Lycra ®: Commercially Nylon 6, Nylon6,6, and Nylon 6-6,6 available in one-way and two-way stretch co-polymerfabrics, this blend can be used in warp only, fill only or a combinationof both. Carbon fibres High tensile strength (lower than aramid fibres);modulus 3-4 times higher than glass fibre. Example: Hi modulus carbonfibre (graphite): 11 gpd tensile strength; 3000 gpd initial modulus;elongation 0.4%. Liquid crystalline polymer (textile grade) High tensilestrength, high modulus. Example: Heat-treated PBZT (poly(p-phenylenebenzobisthiazole filaments): 25-30 gpd tensile strength; 2100-2400 gpdinitial modulus; elongation 1-1.4%. Lightweight metal alloys (e.g.,titanium, Modulus comparable to aramid fibres; aluminum; metal matrixcomposite) high strength (especially if heat-treated); titanium resistsfatigue to a greater degree than does aluminum; relatively high cost.Example: 3-2.5 titanium: 135 kPsi tensile strength; 10-19% elongation.Relatively high modulus thermoplastic Lower modulus than Kevlar, with asofter polyesters (e.g., Hytrel ®, from DuPont hand; high strength, someminor tendency [preferably, Hytrel.RTM, with a toward creep/sag.durometer of 55 on the D-scale, or more Example: specifically,Hytrel.RTM. grade 5544 or Hytrel.RTM ®, grade 5556: Extruded 5556) andRight Flex ®, from Ticona) block copolymer of polyetramethyleneterephthalate polyester and polytetramethylene ether. Medium modulus(110 MPa, at 100° C.), 40 kpsi tensile strength; elongation 500%. Grade5544 has a 125 MPa at 100° C., 31 kpsi tensile strength, and elongation375%.

[0069] Those of ordinary skill in the art will recognize that thetendencies toward “sag and creep” of these materials vary; in general,preferred materials for use in the invention will be those with littlesuch tendency. In view of the teachings of this disclosure, materialsother than those listed above which are suitable for use in constructingthe lattice may be identified.

[0070] Suitable Materials for use as Low Modulus Components of theLattice Include: MATERIAL COMPARATIVE VALUES Extrudable aromaticpolyesters (e.g., Modulus comparable to nylon, polytrimethyleneterepthalate, or lower tensile strength. Properties PTT, from ShellCorterra) similar to spandex, at lower deniers. Spandex (e.g., Lycra ®,from Wider availability than PTT. DuPont) Non-spandex polyester yarnsand Most are very low modulus. upholstery grade fibrous yarnsMicrofibers Excellent feel and drapability, most are very low modulus.

[0071] As noted, most preferably, the composition of the lattice variesfrom region to region, to provide greater support in some areas, orsofter support in others. For example, referring to FIG. 8, anembodiment of the lattice is shown in which medial side 31 of midfootregion 36 (medial to midline C-C), a portion 32 of forefoot region 34(forward of line D-D, to underlie the metatarsal heads), and a portionof heel region 37 (rearward of line E-E) are formed of nylon or tightlywoven Hytrel®. Adjacent regions of the lattice (including midfoot region36 lateral to line C-C) are formed of Hytrel®. The nylon portions of thelattice are relatively inelastic, and provide support to, respectively,the medial arch (to control supination), the metatarsal heads. (to aidin support of the toes), and the heel (to enhance stability). TheHytrel® portions of the lattice have a moderate modulus of elasticity,and provide more gentle support to the remainder of the foot.

[0072] Those of ordinary skill in the art will appreciate that theparticular arrangement of varying materials shown in FIG. 8 may bevaried, depending on the desired degree of control to be provided. Forexample, a relatively inelastic material may be provided at the lateralside of line C-C, and a more elastic material at the medial side of lineC-C, to aid in control of pronation. This embodiment of the invention,as well as all others, may be constructed using known techniques; forexample, lattice 30 may be provided with differing fiber content bychanging the material loaded onto a loom at predetermined points duringthe weaving process.

[0073] Control of gait, as described with respect to FIG. 8, may also beprovided by varying the relative tension and weave of fibers indifferent regions of lattice 30. For example, as shown in FIG. 9A,medium to high modulus fibers 40 are provided (to run mediolaterallybetween lateral side 12 and medial side 13 of annular frame 11), and areinterwoven with lower modulus fibers 41 (to run diagonally orlongitudinally across fibers 40). Using Hytrel® as a reference point,fibers 40 are prestretched between 6 to 9% elongation to assist inmaintaining the desired contour of lattice 30. Fibers 40 may also beprovided both the diagonal/longitudinal and mediolateral directions oflattice 30, and the fibers in each direction may be pretensioned to thesame or different degrees, depending on the desired attitude of eachregion of lattice 30.

[0074] To the same end, referring to FIGS. 4 and 10, the density andweave of the fibers may also vary. For example, fibers 40 may bevariably woven to present ellipitical, rounded or squared pore shapes ofequal or varying sizes, depending on the relative tension to be providedin each region of lattice 30. The density of the fibers may also bevaried to provide more cross-fibers in regions under greater tension,and vice-versa. As shown in FIG. 10, fibers 40 in mid foot region 36medial to line C-C have a density of about 35 yarns/square inch(providing a stiffer mesh), compared to a 20 yarns/square inch densityin fibers 42 lateral to line C-C.

[0075] Because the wearer's foot rests directly on lattice 30 (separatedonly, if present, by a sock or the like), the feel of the mesh againstthe foot is a consideration. A plurality of additional fibers, and/orfibrous yarn strands, may also be interwoven with fibers 40, to form athird layer of mesh, to soften the hand of lattice 30, or such strandsmay replace a portion of fibers 40 running in either the diagonal ormediolateral direction. For example, fibrous yarn strands may beinterwoven with fibers 40 at a density of approximately 7-10 strands perinch. Using a polyester yarn such as Lycra® as a reference point, suchstrands are preferably pre-stretched between 3% and 5% elongation inorder to maintain the desired attitudinal contours in lattice 30.

[0076] To further enhance comfort, the cross-sections of fibers 40, andany strands of other material present, preferably have a width to heightratio in the range of about 1.5:1 to 2:1 (see, e.g., FIG. 9B). Soconfigured, the wearer will be less likely to feel pressure fromindividual fibers and strands. For example, applying the desired widthto height ration, where fibers 40 have a width of approximately 0.02479inches and a height or thickness of approximately 0.01636 inches,lattice 30 contains about 24-26 fibers per inch. As a further example,where fibers 40 have a width of 0.02800 inches and a height or thicknessof approximately 0.01700 inches, lattice 30 contains about 20 fibers perinch.

[0077] To maintain the pore spacing fibers 40 preferably weavealternately above and below adjacent strands in the group. Thisconfiguration provides a relatively large surface area which distributespressure on the wearer's foot, and to encourage the material to“breathe”; i.e., allow for air circulation. As an alternative to use ofa woven mesh, the mesh may be formed by extrusion or molding of a sheet(0.25 mm or greater in thickness) of an elastomeric polymer, such asHytrel®, which is perforated to provide pores for aeration.

[0078] Additional cushioning may be provided in discrete areas of thelattice. For example, air or fluid-filled bladders may-be securedbeneath areas of the lattice (see, FIG. 13, showing a foam pad disposedforward of midfoot region 34). However, if used, such additionalcushioning should be used sparingly, to avoid defeating the suspensioncharacteristics of the device.

[0079] III. Construction of the Device of the Invention

[0080] As shown in FIG. 2, lattice 30 is attached along, or adjacent to,the upper rim of annular frame 11, in the desired, pre-stretchedconformation. The attachment means employed to secure lattice 30 toannular frame 11 will vary with the material utilized in lattice 30, butmay include co-molding of lattice 30 and scaffolding 10, spot welding,adhesives or mechanical attachments.

[0081] For example with respect to the latter, lattice 30 may beextruded or otherwise constructed so the ends of each strand areattached to, or an integral part of, a removable upper rim portion ofannular frame 11. Conveniently, as shown in FIG. 6, such upper rimportion 85 may be removably secured to annular frame 11, as in atongue-and-groove attachment, so lattice 30 (not shown in FIG. 6) may beexchanged with a new or differently configured lattice by the wearer.

[0082] Individual fibers may also be secured to annular frame 11 byextension through grommets disposed therein (see, grommets 86 of FIG.5). In such an embodiment, adjustment means may be provided to allow thewearer to adjust the relative tension placed on individual fibers bypulling the fibers more tautly through each grommet or, conversely, byloosening each fiber. To this end, each grommet may be supplied withthreading within its bore, matched by threads along the fiber, to serveas click-stops to retain the fiber within the grommet at predeterminedpoints. Alternatively, each fiber may be stretched or loosened withineach grommet, and knotted outside of each grommet, to permit changes tobe made to the tension placed on the fiber. For durability, each fibermay be coated or modified at its end attachment point with a highmodulus material, for example, glass fibre nylon.

[0083] Molded attitudinal adjustments in lattice 30 are provided byadjusting the contours at discrete regions of the lattice. For example,as shown in FIG. 2, a concavity is provided in heel region 37 to serveas a well to accept and stably hold the heel of a foot, and anotherconcavity is provided beneath the metatarsal heads in forefoot region34, and rise in attitude forward of that point, to stabilize theforefoot. Contouring of the mesh can be achieved in various ways knownto those of skill in the art, depending on the composition of the fibersused. For example, the lattice may be molded, heat-set or individualfibers resin coated and cured to provide, and maintain, desired contourstherein.

[0084] A non-exhaustive example of a method for providing contours inlattice 30 during manufacture is as follows. A molding tool including anupper mold member and a lower mold member is provided with recesseswhich are configured to receive upper and lower members of a loom, andopposing recesses which define one or more cavities of desireddimensions. On looming of the lattice material, including compressionthereof into the desired cavities, a plastic resin is then injected intothe cavities to secure the periphery of the lattice, and the moldmembers are pulled apart to release the finished lattice.

[0085] IV. Shoes Incorporating the Device of the Invention Therein

[0086] As shown in FIG. 11, scaffolding-10 is placed into a shoe 95 soannular frame 11 closely fits along the inner perimeter of the shoeupper 92. Where side pillars 19A, 19B, 20A and 20B extend transverselyacross scaffolding 10 to form “U” shaped members, the bight thereof willrest on the base 94 of the shoe. The shoe base may be a unitary length,or may, be formed of bands on which each “U” shaped member is disposed.Said shoe base may also be provided with additional cushioning elements,such as air or fluid-filled bladders, especially for use in those areasof the shoe in which the lattice does not serve as a midsole; e.g., foruse in the forefoot region with embodiments of the inventive devicewhich terminate in length at the metatarsal heads, as shown in FIG. 13(see, pad 90, forward of ¾ length scaffolding 100).

[0087] As noted elsewhere above, a preferred embodiment of the inventionis one in which annular frame 11 is attached to, or made an integralpart of, a shoe upper. For example, with reference to FIG. 12, where theshoe upper 92 is a fabric or microfiber material, such material may bewoven or sewed as layers encompassing annular frame 11 (shown inphantom) within the sidewalls of the upper. As shown in FIG. 12, sidepillars 19A, 19B, 20A and 20B protrude out of the bottommost edge 93 ofthe material which forms upper 92, but may be absent, or shortened toform flanges (elements 79A through 82B of FIG. 7) to engage the shoebase (not shown).

[0088] Alternatively, annular frame 11 may be secured to, or co-moldedas an integral part of, the base of the shoe. In such an embodiment(with reference to the scaffoldings illustrated in FIGS. 1 and 7), sidepillars 19A, 19B, 20A and 20B (FIG. 1) would be absent, or shortened toform flanges (elements 79A through 82B of FIG. 7) to securely engage theshoe base; e.g., through co-molding of the flanges with the shoe base,by insertion into slots therein, or by other suitable attachment means.

[0089] The invention having been fully described, additionalembodiments, modification and adaptations thereof may become apparent tothose of ordinary skill in the art. All such iterations of the inventionare intended to be encompassed by the appended claims.

The invention claimed is:
 1. A sole construction for use in a shoe, tosupport a foot by placing the foot in suspension within the shoe,wherein the shoe includes an upper and a base, the sole constructioncomprising: a lattice composed of one or more high to medium moduluspolymer or metal alloy materials, wherein the lattice is constructed tosubstantially conform to the contours of the sole of the foot, or aweight-bearing portion thereof; and, scaffolding means attached to thelattice, wherein the scaffolding means maintain the lattice insuspension above the base of the shoe; wherein the lattice carries thefoot, or a weight-bearing portion thereof, in suspension above the baseof the shoe.
 2. The sole construction according to claim 1, wherein thescaffolding means, comprises a resilient annular frame having medial andlateral opposing sides attached to the lattice and adapted to fit alongthe inner perimeter of the upper; and further comprises support pillarsextending downwardly from the annular frame.
 3. The sole constructionaccording to claim 2, wherein one or more of the support pillars extendbeneath the lattice to form a “U” shaped member having a bight seatableon the base of the shoe.
 4. The sole construction according to claim 1,wherein one or more regions of the lattice are carried by thescaffolding in a higher plane than other regions of the lattice.
 5. Thesole construction according to claim 3, wherein one or more of theannular side members include-rotation means to allow the side members,when disposed in the shoe, to move in a vertical plane adjacent to flexpoints in the foot.
 6. The sole construction according to claim 5,wherein the rotation means consists of a hinge, spring, piston, rotatingpin, solenoid, or a flexible polymer member.
 7. The sole constructionaccording to claim 6, wherein the flexible polymer consists of a closedcell polyurethane, ethylene vinyl acetate, or rubber.
 8. The soleconstruction according to claim 2, wherein the support pillars includemeans for shock absorption.
 9. The sole construction according to claim2, wherein the support pillars include adjustment means for allowingportions of the frame to be raised and lowered to set heights within theshoe.
 10. The sole construction according to claim 1, wherein thelattice is removably attached to the scaffolding.
 11. The soleconstruction according to claim 10, wherein the scaffolding furtherincludes a removable annular rim, and the lattice is attached to saidremovable annular rim.
 12. The sole construction according to claim 1,wherein the lattice is permanently attached to the scaffolding.
 13. Thesole construction according to claim 12, wherein the lattice isconstructed of interwoven fibers, and each of said fibers is secured tothe scaffolding by insertion through a grommet disposed in the annularframe.
 14. The sole construction according to claim 1, wherein thelattice is integrally formed as part of the scaffolding.
 15. The soleconstruction according to claim 14, wherein the lattice is co-moldedwith the scaffolding.
 16. The sole construction according to claim 1,further including energy return means for absorbing energy fromcompression during gait, and releasing the energy when the compressionends; wherein said energy return means are disposed adjacent to thelattice at points therein adapted to carry weight-bearing portions ofthe foot.
 17. The sole construction, according to claim 16, wherein theenergy return means comprise distinct portions of the lattice, whereinsaid distinct portions are under a greater relative tension thanadjacent portions of the lattice.
 18. The sole construction according toclaim 16, wherein the energy return means comprise closed cell foammaterial or fluid-filled capsules incorporated within distinct portionsof the lattice.
 19. The sole construction according to claim 1, whereinthe fibers are medium modulus fibers.
 20. The sole constructionaccording to claim 19, wherein the medium modulus fibers comprise acomposite of polyetramethylene terephthalate polyester andpolytetramethylene ether.
 21. The sole construction according to claim20, wherein the medium modulus fibers consist of Hytrel®.
 22. The soleconstruction according to claim 21, wherein the Hytrel® has a modulus ofat least about 10 MPa, at 100° C., elongation to break at 375%, andtensile strength of at least 31 kpsi.
 23. The sole constructionaccording to claim 19, wherein the medium modulus fibers run in the warpdirection of the woven lattice.
 24. The sole construction according toclaim 23, wherein the medium modulus fibers also run in the weftdirection of the woven lattice.
 25. The sole construction according toclaim 23, wherein the fibers running in the weft direction of thelattice are high modulus fibers.
 26. The sole construction according toclaim 23, wherein the fibers running in the weft direction of thelattice are low modulus fibers.
 27. The sole construction according toclaim 1, wherein the polymer fibers are high modulus polymer fibers. 28.The sole construction according to claim 27, wherein the high modulusfibers are selected from the group of such fibers consisting of nylon,carbon fibers, liquid crystalline polymers, aramid polymers, andlightweight metal alloys.
 29. The sole construction according to claim19, wherein the lattice is further comprised of interwoven low modulusfibers.
 30. The sole construction according to claim 27, wherein thelattice is further comprised of interwoven low modulus fibers.
 31. Thesole construction according to claim 29 or claim 30, wherein the lowmodulus fibers are selected from the group of such fibers consisting ofspandex, extrudable aromatic polyesters, upholstery grade fibrous yarns,microfibre yarns, and non-extrudable polyester yarns.
 32. The soleconstruction according to claim 1, wherein the lattice includes (a) aforefoot region consisting of a forward aspect to extend distally fromthe metatarsal heads of the foot, and a rearward aspect to underlie themetatarsal heads of the foot; (b) a midfoot region extending proximallyfrom the ball of the foot toward the heel, which midfoot region hasmedial and lateral aspects; and (c) a heel region.
 33. The soleconstruction according to claim 32, wherein the medial aspect of themidfoot region is formed of a high modulus polymer or metal, and thelateral aspect of the midfoot region is formed of a medium moduluspolymer.
 34. The sole construction according to 32, wherein the heelregion includes a concavity therein adapted to receive the heel of afoot, and said concavity is formed of a high modulus polymer or metal;wherein further portions of the heel region adjacent to the concavityare formed of a medium modulus polymer.
 35. The sole constructionaccording to claim 32, wherein the rearward aspect of the forefootregion is formed of a high modulus polymer, and the forward aspect ofthe forefoot region is formed of a medium modulus polymer.
 36. The soleconstruction according to claim 32, wherein the fibers of the medialaspect of the midfoot region is woven at a density greater than 20threads per square inch; and the fibers of the lateral aspect of themidfoot region is woven at a density of 20 threads per square inch, orless.
 37. The sole construction according to claim 32, wherein the heelregion includes a concavity therein adapted to receive the heel of afoot, and the fibers of said concavity are woven at a density greaterthan 20 threads per square inch; and the fibers of the portion of theheel region adjacent to the concavity are woven at a density of 20threads per square inch, or less.
 38. The sole construction according toclaim 32, wherein the fibers of the rearward aspect of the forefootregion are woven at a density greater than 20 threads per square inch;and the fibers of the forward aspect of the forefoot region are woven ata density of 20 threads per square inch, or less.
 39. The soleconstruction according to claim 1, wherein the fibers running in thewarp direction of the lattice are under higher relative tension than thefibers running in the weft direction of the lattice.
 40. The soleconstruction according to claim 32, wherein the density of the fibers inthe lattice varies-among its regions.
 41. The sole constructionaccording to claim 32, wherein the composition of the fibers in thelattice varies among its regions.
 42. The sole construction according toclaim 32, wherein the relative tension placed on the fibers in thelattice varies among its regions.
 43. The sole construction according toclaim 32, wherein the medial aspect of the midfoot region of the latticeis adapted to receive the arch of a foot, and is suspended in a higherplane than the lateral aspect of the midfoot region of the lattice. 44.The sole construction according to claim 32, wherein the forward portionof the forefoot region of the lattice is adapted to receive themetatarsal heads of a foot, and is suspended in a higher plane than therearward portion of the forefoot region of the lattice.
 45. The soleconstruction according to claim 2, wherein the annular frame is adaptedto fit along the lateral and medial aspects of a forefoot region of afoot, and the lattice consists of a forefoot region consisting of aforward portion distal to the ball of the foot, as well as a rearwardportion underlying the ball of the foot; and wherein further a portionof the forward portion of the lattice is adapted to receive themetatarsal heads of a foot, and is suspended in a higher plane than therearward portion of the lattice.
 46. The sole construction according toclaim 2, wherein the annular frame is adapted to fit along the lateraland medial aspects of a midregion of a foot extending proximally fromthe ball of the foot toward the heel; and wherein further the medialaspect of the mid-region of the lattice is adapted to receive the archof a foot, and is suspended in a higher plane than the lateral aspect ofthe mid-region of the lattice.
 47. A shoe having an improved soleconstruction, the shoe comprising an upper, a base, and the improvedsole construction of claim
 1. 48. The shoe according to claim 47,wherein the scaffolding means comprises a resilient annular frame havingmedial and lateral opposing sides attached to the lattice.
 49. The shoeaccording to claim 48, wherein the resilient annular frame is adapted tofit along the inner perimeter of the upper; and further comprisessupport pillars extending downwardly from the annular frame.
 50. Theshoe according to claim 48, wherein the resilient annular frame is anintegral part of the shoe upper, so the scaffolding and shoe upper forma unitary structure.
 51. The shoe according to claim 49, wherein thesupport pillars extend beneath the lattice to form a “U” shaped memberhaving a bight seatable on or under the base of the shoe.
 52. The shoeaccording to claim 49, wherein the support pillars securely engage thebase of the shoe to retain the sole construction in place therein. 53.The shoe according to claim 48, further including energy return meansfor absorbing energy from compression during gait, and releasing theenergy when the compression ends; wherein said energy return means areincorporated within the base of the shoe at one or more locationstherein.
 54. The shoe according to claim 53, wherein the energy returnmeans comprise closed cell foam material or fluid-filled capsules.
 55. Amethod for manufacture of a shoe having an upper, a base, and animproved sole construction, the method comprising forming the soleconstruction of claim 1 as a unitary part of the shoe upper, thensecuring the upper to the shoe base.
 56. The method according to claim55, wherein the sole construction and upper are co-molded.
 57. Themethod according to claim 55, wherein the upper is constructed of alayered fabric, and the annular frame of the sole construction isencompassed between two layers of the upper fabric
 58. A method formanufacture of a shoe having an upper, a base, and a lattice secured tothe upper, wherein the lattice is composed of one or more high to mediummodulus polymer or metal alloy materials, and the lattice is constructedto substantially conform to the contours of the sole of the foot, or aweight-bearing portion thereof; the method comprising securing thelattice to the upper, and securing the upper to the base, so that thelattice carries the foot, or a weight-bearing portion thereof, insuspension above the base of the shoe.